Muffler with metallic meshed rings

ABSTRACT

Disclosed is a muffler for a water-cooled chiller or air-cooled of a vapor-compression or absorption refrigeration system, the muffler having: an upstream case having a fluid inlet; a downstream case connected to the upstream case at a downstream end of the upstream case, the downstream case having a fluid outlet; the upstream case having a plurality of axially adjacent outer muffler rings and a plurality of axially adjacent inner muffler rings, the outer muffler rings being axially coextensive and a radially exterior to the inner muffler rings and defining a fluid inlet passage therebetween, wherein the outer muffler rings and inner muffler rings are a metal mesh material.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/838,776, filed Apr. 2, 2020, which claims the benefit of U.S.National Stage Application of PCT/US2018/054998 filed Oct. 9, 2018,which claims the benefit of and U.S. Provisional Application No.62/570,846 filed Oct. 11, 2017, the disclosures of each of which areincorporated herein by reference in their entirety.

BACKGROUND

Exemplary embodiments pertain to the art of mufflers for water-cooled orair-cooled chillers and more specifically for muffler rings within themufflers.

A chiller is a machine that removes heat from a liquid via avapor-compression or absorption refrigeration cycle. This liquid canthen be circulated through a heat exchanger to cool air or equipment asrequired. As a necessary byproduct, refrigeration creates waste heatthat must be exhausted to ambient or, for greater efficiency, recoveredfor heating purposes. Chillers may have mufflers where the mufflercanister assemblies (or mufflers) may be manufactured with polypropyleneor fiberglass muffler rings. Such rings may have beads or particles thatmay deteriorate over time and clog system orifices, filter-drier(s) orstrainer(s). Also, decaying of polypropylene or fiberglass rings mayresult in increased noise level of the chiller.

BRIEF DESCRIPTION

Disclosed is a muffler for a water-cooled chiller or air-cooled of avapor-compression or absorption refrigeration system, the mufflerhaving: an upstream case having a fluid inlet; a downstream caseconnected to the upstream case at a downstream end of the upstream case,the downstream case having a fluid outlet; the upstream case having aplurality of axially adjacent outer muffler rings and a plurality ofaxially adjacent inner muffler rings, the outer muffler rings beingaxially coextensive and a radially exterior to the inner muffler ringsand defining a fluid inlet passage therebetween, wherein the outermuffler rings and inner muffler rings are a metal mesh material.

In addition to one or more of the features described above, or as analternative, further embodiments may include that one or both of theouter muffler rings and inner muffler rings are steel.

In addition to one or more of the features described above, or as analternative, further embodiments may include that one or both of theouter muffler rings and inner muffler rings are stainless steel.

In addition to one or more of the features described above, or as analternative, further embodiments may include that one or both of theouter muffler rings and inner muffler rings are SAE 304A stainlesssteel.

In addition to one or more of the features described above, or as analternative, further embodiments may include that one or both of theouter muffler rings and inner muffler rings are 0.008 inch wallthickness type SAE 304A stainless steel with a mesh density of twelve(12) percent and a weight of 6.23 ounces.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the upstream caseincludes N sets of muffler rings, the N sets of muffler rings beingaxially aligned and radially spaced to provide N−1 fluid passagestherein, wherein N is greater than or equal to 3.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the upstream case is aprimary upstream case and the muffler includes a secondary upstream casefluidly connected to the primary upstream case proximate a downstreamend of the primary upstream case, the secondary upstream case includinga plurality of axially adjacent muffler rings that are a metal meshmaterial.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the secondary mufflercase includes a plurality of the secondary upstream cases each fluidlyconnected to the primary upstream case proximate the downstream end ofthe upstream case.

In addition to one or more of the features described above, or as analternative, further embodiments may include that the secondary mufflercase includes N sets of muffler rings, the N sets of muffler rings beingaxially aligned and radially spaced to provide N−1 fluid passagestherein, wherein N is greater than or equal to 3.

Further disclosed is a heating or cooling system including: a chillerthe having a muffler with one or more of the above disclosed features.

Yet further disclosed is a method of operating a chiller system, thechiller system including a muffler, the muffler further including anupstream case having a fluid inlet, a downstream case connected to theupstream case at a downstream end of the upstream case, the downstreamcase having a fluid outlet, the upstream case having a plurality ofaxially adjacent outer muffler rings and a plurality of axially adjacentinner muffler rings, the outer muffler rings being axially coextensiveand a radially exterior to the inner muffler rings and defining a fluidinlet passage therebetween, and wherein the outer muffler rings andinner muffler rings are a metal mesh material, the method including:muffling noise so that over an octave band of 80 Hz to 130 Hz, a soundpressure level is between approximately 78 dBA-Wtg and approximately 80dB A-Wtg.

In addition to one or more of the features described above, or as analternative, further embodiments may include that muffling noise over aone third octave band, from static to 1000 Hz, results in an averagesound pressure level of 81.7 dBA.

BRIEF DESCRIPTION OF THE DRAWINGS

The following descriptions should not be considered limiting in any way.With reference to the accompanying drawings, like elements are numberedalike:

FIG. 1 illustrates a portion of a chiller assembly having a mufflercanister assembly (or muffler) according to an embodiment;

FIG. 2 illustrates a cross-sectional view of muffler according to anembodiment;

FIG. 3 illustrates a muffler according to an embodiment;

FIG. 4 graphs results from testing chillers with mufflers of differentmaterials including a muffler according to an embodiment;

FIG. 5 graphs results from testing chillers with mufflers of differentmaterials including a muffler according to an embodiment;

FIG. 6 graphs results from testing a chiller with a muffler according toan embodiment;

FIG. 7 illustrates a cross-sectional view of muffler according to anembodiment;

FIG. 8 illustrates a perspective view of muffler according to anembodiment; and

FIG. 9 illustrates a cross-sectional view of muffler according to anembodiment.

DETAILED DESCRIPTION

A detailed description of one or more embodiments of the disclosedapparatus and method are presented herein by way of exemplification andnot limitation with reference to the Figures.

FIG. 1 illustrates a portion of a chiller assembly (or chiller) 100,which may take the form of Chiller Model 23XR4747ERVAA50 water-cooledvariable speed screw chiller by Carrier Corporation, which is a brand ofthe Climate, Controls and Security division of United TechnologiesCorporation (UTC). The chiller 100 may have a muffler canister assembly(or muffler) 105.

As illustrated in FIGS. 2 and 3 the muffler 105 may have an upstreamcase 110 with a first diameter and a first length, and a downstream case115 with a second diameter and a second length. The second diameter maybe smaller than the first diameter. A muffler inlet 120 may be in theupstream case 110 and a muffler outlet 125 may be in the downstream case115. The inlet 120 may be disposed in the axial direction and the outlet125 may extend in the radial direction and be located in an axiallyintermediate position of the downstream case 115 between an upstream end116 of the downstream case and a downstream end 118 of the downstreamcase. Inlet flow 130 and outlet flow 135 are also illustrated.

Inlet flow passage 140 may be defined between a plurality of outermuffler rings (or outer rings) 145 including first outer ring 150 havinga third diameter and a plurality of inner muffler rings (or inner rings)155 including first inner ring 160 having a fourth diameter. Theplurality of outer muffler rings 145 may be axially coextensive with theplurality of inner muffler rings 155 along the span of the upstream case110. The resulting structure from the outer rings 145 may form anacoustic absorbing outer wall. The plurality of inner rings 155 may forman internal damping cavity 156 and the structure is sometimes referredto as an acoustic bullet.

A blast area 161 may be located at the axial intersection 165 of theupstream case 110 and downstream case 115. Axially between the blastarea 161 and the outlet 125, and within the downstream case 115 may be aplurality of flow effecting chambers 170 including first chamber 175(which may include additional layers of metallic rings). In the sameaxial location there may be a plurality of exhaust ports 180 includingfirst exhaust port 185. The chambers 170 may be axially adjacent and mayhave an outer diameter defined by the inner diameter of the downstreamcase 115.

Pressure from the blast area 161 may tend to pull part the outer rings145 as illustrated by arrows 190. The same pressure may tend to crushinner rings 155 as illustrated by arrows 195. To accommodate thesepressures 190, 195 the rings 145, 155 may be fabricated from metal mesh.For example the rings 145, 155 may be manufactured from stainless steel,more specifically type SAE 304A stainless steel, yet more specifically0.008 inch wall thickness type SAE 304A stainless steel with a meshdensity of twelve (12) percent and a weight of 6.23 ounces. Thismaterial configuration however is not limiting. The use of metals havingmaterials similar to the standard identified under SAE304 but withvarious wall thicknesses and/or densities is possible, as well as andAluminum with various wall thicknesses and/or densities for lower soundlevels.

Illustrated in FIG. 4 , the above noted Chiller Model 23XR4747ERVAA50was tested on different occasions with mufflers 105 fitted with eitherfiberglass muffler rings 145, 155, polypropylene muffler rings 145, 155or metal mesh muffler rings 145, 155. Throughout operating speeds ofapproximately 80 to 100 Hz, the chiller having the muffler 105 withmetal mesh muffler rings 145, 155 produced consistently lower noise thanthe counterpart tests. More noise was produced by the chiller having themuffler 105 with polypropylene muffler rings 145, 155 and yet more noisewas produced by the chiller having the muffler 105 configured withfiberglass muffler rings 145, 155.

Remaining with FIG. 4 , for the chiller having the muffler 105 withmetallic mesh muffler rings 145, 155 the sound pressure level (SPL) wasmeasured as being between approximately 80 dBA-Wtg (“A-weighted”) andapproximately below 82 dBA-Wtg as illustrated by graph line 200. For thechiller having the muffler 105 with polypropylene muffler rings 145, 155the SPL was between approximately 80.5 dBA-Wtg and approximately below84 dBA-Wtg as illustrated by graph line 210. For the chiller having themuffler 105 with fiberglass muffler rings 145, 155 the measured SPL wasbetween approximately 81.5 dBA-Wtg and approximately 84.5 dBA-Wtg asillustrated by graph line 220.

As illustrated in FIG. 5 , similar tests performed over a speed range ofapproximately 25 Hz to approximately 135 Hz and the results werecompared against predicted results. For the chiller having the muffler105 with polypropylene muffler rings 145, 155 the measured SPL wasrecorded and graphed with circular markers 310. The predicted resultsfor the same configuration are graphed with triangular markers 320. Forthe chiller having the muffler 105 with metal mesh muffler rings 145,155 “X” markers 330 illustrate both SPL predicted and actual results. AsFIG. 5 illustrates, the chiller having the mufflers 105 with metallicmesh rings 145, 155 had SPLs that were more predictable and moreconsistently lower than the alternatives. Though some measurements 340of the polypropylene configuration provided lower SPL at speed, thosemeasurements skewed far from predicted results, were not consistent, andwere in the area of predicted resonance. These results 340 weretherefore not reliable and could not be reasonably expected of beingrepeated at any given run.

Remaining with FIG. 5 , damped resonance was predicated and observedwith the chiller having the muffler 105 with polypropylene muffler rings145, 155 at, and around, approximately 100 Hz. In comparison noresonance was predicted or observed in the test speed range with thechiller having the mufflers 105 fitted with the metallic mesh mufflerrings 145, 155. As illustrated, muffling noise over an octave band of 80Hz to 130 Hz provided a sound pressure level of between approximately 78dBA-Wtg and approximately 80 dB A-Wtg. In addition to being quieter, oneof ordinary skill would appreciate that metallic mesh muffler rings 145,155 and components with fluid and mechanical connections therewith willlast longer when not subjected to resonance.

Turning to FIG. 6 , the graph line 400 illustrates that over a one thirdoctave band, from static to 1000 Hz, the average SPL for the chillerhaving the muffler 105 with metallic mesh muffler rings is 81.7 dBA.Test conditions for the measurements taken in FIG. 6 were 100% speed at85 degrees Fahrenheit at the inlet of condenser and 44 degreesFahrenheit at the outlet of the evaporator. This sound level is lowerthan the sound level that exists at the low end of the tested speedrange for the chiller having the muffler with the fiberglass mufflerrings 145, 155 in FIG. 4 . In addition, this sound level is below atleast two-thirds of the sound levels sensed in the tested speed rangefor the chiller having the muffler with the polypropylene muffler rings145, 155 in FIG. 4 .

In comparison with polypropylene muffler rings or fiberglass mufflerrings, metallic mesh muffler rings may be superior. Metallic meshmuffler rings may provide for better sound muffling as indicated by theabove data. In addition, there may be a much lower likelihood ofmetallic rings burning during welding steps of the muffler manufacturingprocesses. Further, metallic mesh muffler rings may have a lowerlikelihood of deteriorating and clogging orifices or filter-driers andmay be more durable and last longer. In addition, metallic mesh mufflerrings may have a higher melting temperature and tensile strength.Metallic mesh muffler rings may have a lower chance of becomingsaturating with refrigerant and oil and may be less likely to havecompatibility issue with refrigerants and oils. Moreover the assemblycost of mufflers using metallic mesh muffler rings may be lower as themuffler rings are easy to manufacture and manipulate and the material ismore readily available. Mufflers with metallic mesh muffler rings may beused with at least pneumatic tools, compressors, blow-off valves, smallengines and catalysts.

Turning to FIG. 7 , alternative muffler assembly 500 is illustrated. Themuffler assembly 500 includes an upstream case 505 and a downstream case510. The downstream case 510 is substantially similar to the previouslydisclosed downstream case 115. The upstream case 505 differs from theabove disclosed upstream case 110 in that the upstream case has aplurality of layers of muffler rings including outer muffler rings 520,inner muffler rings 530 and an intermediate set of muffler rings 540which are radially between the outer muffler rings 520 and inner mufflerrings 530. This configuration provides a center chamber 550 and two flowpassages 560, 570, axially aligned and radially spaced between the threesets of muffler rings 520, 530, 540. As illustrated the first passage560 is between the set of inner muffler rings 530 and intermediatemuffler rings 540. The second passage 570 is between the set of outermuffler rings 520 and intermediate muffler rings 540.

The embodiment of FIG. 7 provides N sets of axially aligned and radiallyspaced muffler rings and N−1 sets of axially aligned and radially spacedflow passages. While the materials of the embodiment in FIG. 7 are thesame as the materials of the embodiment in FIG. 1 , this configurationresults in specifically desired output sound effects based on desiresnoise dampening.

In the embodiments in FIGS. 8 and 9 , an alternative muffler assembly600 is illustrated. The muffler assembly 600 includes an upstream case605 and a downstream case 610. The downstream case 610 is substantiallysimilar to the previously disclosed downstream case 115. The upstreamcase 605 differs from the above disclosed upstream case 110 in thatproximate the downstream end 620 of the upstream case 605 is an inlet630 through which a secondary muffler assembly 640 is fluidly connected.The secondary muffler assembly 640 may have one set of internal mufflerrings 650 surrounding a center muffler chamber 660, or the configurationof the secondary muffler assembly 640 may be similar to one of the abovedisclosed embodiments with respect to the upstream cases 110, 505. Thematerials in the secondary muffler assembly 640 may be the same as thosein the above disclose upstream case 110. An upstream inlet 670 to thesecondary muffler assembly 640 may be fed by a secondary branch feed(not illustrated) from the chiller 100.

The embodiment of FIGS. 8 and 9 provide a plurality of upstream mufflercases configured to provided muffler damping characteristics that whencombined result in damping characteristics that may be more preciselytuned than one upstream case could provide in a given set of designconstraints. In addition, one or more secondary upstream muffler casescould be retrofitted into an active chiller system as needed.

The term “about” is intended to include the degree of error associatedwith measurement of the particular quantity based upon the equipmentavailable at the time of filing the application.

The terminology used herein is for the purpose of describing particularembodiments only and is not intended to be limiting of the presentdisclosure. As used herein, the singular forms “a”, “an” and “the” areintended to include the plural forms as well, unless the context clearlyindicates otherwise. It will be further understood that the terms“comprises” and/or “comprising,” when used in this specification,specify the presence of stated features, integers, steps, operations,elements, and/or components, but do not preclude the presence oraddition of one or more other features, integers, steps, operations,element components, and/or groups thereof.

While the present disclosure has been described with reference to anexemplary embodiment or embodiments, it will be understood by thoseskilled in the art that various changes may be made and equivalents maybe substituted for elements thereof without departing from the scope ofthe present disclosure. In addition, many modifications may be made toadapt a particular situation or material to the teachings of the presentdisclosure without departing from the essential scope thereof.Therefore, it is intended that the present disclosure not be limited tothe particular embodiment disclosed as the best mode contemplated forcarrying out this present disclosure, but that the present disclosurewill include all embodiments falling within the scope of the claims.

1. A muffler for a chiller of a vapor-compression or absorptionrefrigeration system, the muffler comprising: an upstream case having afluid inlet; a downstream case connected to the upstream case at adownstream end of the upstream case, the downstream case having a fluidoutlet; the upstream case having a plurality of axially adjacent outermuffler rings and a plurality of axially adjacent inner muffler rings,the outer muffler rings being axially coextensive and a radiallyexterior to the inner muffler rings and defining a fluid inlet passagetherebetween, wherein the outer muffler rings and inner muffler ringsare a metal mesh material, wherein the upstream case comprises N sets ofmuffler rings including the outer muffler rings and the inner mufflerrings, the N sets of muffler rings being axially aligned and radiallyspaced to provide N−1 fluid passages therein, wherein N is greater thanor equal to 3 to define at least a first intermediate set of mufflerrings which are radially between the outer muffler rings and innermuffler rings, to thereby provide a center chamber and at least two flowpassages axially aligned and radially spaced between the sets of mufflerrings, wherein a first flow passage of the at least two flow passages isbetween the inner muffler rings and the first intermediate set ofmuffler rings and a second flow passage of the at least two flowpassages is between the outer muffler rings and the first intermediateset of muffler rings.
 2. The muffler of claim 1 wherein one or both ofthe outer muffler rings and inner muffler rings are steel.
 3. Themuffler of claim 2 wherein one or both of the outer muffler rings andinner muffler rings are stainless steel.
 4. The muffler of claim 3wherein one or both of the outer muffler rings and inner muffler ringsare SAE 304A stainless steel.
 5. The muffler of claim 4 wherein one orboth of the outer muffler rings and inner muffler rings are 0.008 inchwall thickness type SAE 304A stainless steel with a mesh density oftwelve (12) percent and a weight of 6.23 ounces.
 6. (canceled)
 7. Themuffler of claim 1 wherein the upstream case is a primary upstream caseand the muffler includes a secondary upstream case fluidly connected tothe primary upstream case proximate a downstream end of the primaryupstream case, the secondary upstream case including a plurality ofaxially adjacent muffler rings that are a metal mesh material.
 8. Themuffler of claim 7 wherein the secondary muffler case comprises aplurality of the secondary upstream cases each fluidly connected to theprimary upstream case proximate the downstream end of the upstream case.9. The muffler of claim 7 wherein the secondary muffler case includes Nsets of muffler rings, the N sets of muffler rings being axially alignedand radially spaced to provide N−1 fluid passages therein, wherein N isgreater than or equal to
 3. 10. A system comprising: a chillercomprising a muffler, the muffler comprising: an upstream case having afluid inlet; a downstream case connected to the upstream case at adownstream end of the upstream case, the downstream case having a fluidoutlet; and the upstream case having a plurality of axially adjacentouter muffler rings and a plurality of axially adjacent inner mufflerrings, the outer muffler rings being axially coextensive and a radiallyexterior to the inner muffler rings and defining a fluid inlet passagetherebetween, wherein the outer muffler rings and inner muffler ringsare a metal mesh material, wherein the upstream case comprises N sets ofmuffler rings including the outer muffler rings and the inner mufflerrings, the N sets of muffler rings being axially aligned and radiallyspaced to provide N−1 fluid passages therein, wherein N is greater thanor equal to 3 to define at least a first intermediate set of mufflerrings which are radially between the outer muffler rings and innermuffler rings, to thereby provide a center chamber and at least two flowpassages axially aligned and radially spaced between the sets of mufflerrings, wherein a first flow passage of the at least two flow passages isbetween the inner muffler rings and the first intermediate set ofmuffler rings and a second flow passage of the at least two flowpassages is between the outer muffler rings and the first intermediateset of muffler rings.
 11. The system of claim 10 wherein one or both ofthe outer muffler rings and inner muffler rings are steel.
 12. Thesystem of claim 11 wherein one or both of the outer muffler rings andinner muffler rings are stainless steel.
 13. The system of claim 12wherein one or both of the outer muffler rings and inner muffler ringsare SAE 304A stainless steel.
 14. The system of claim 13 wherein one orboth of the outer muffler rings and inner muffler rings are 0.008 inchwall thickness type SAE 304A stainless steel with a mesh density oftwelve (12) percent and a weight of 6.23 ounces.
 15. (canceled)
 16. Thesystem of claim 10 wherein the upstream case is a primary upstream caseand the muffler includes a secondary upstream case fluidly connected tothe primary upstream case proximate a downstream end of the primaryupstream case, the secondary upstream case including a plurality ofaxially adjacent muffler rings that are a metal mesh material.
 17. Thesystem of claim 16 wherein the secondary muffler case comprises aplurality of the secondary upstream cases each fluidly connected to theprimary upstream case proximate the downstream end of the upstream case.18. The system of claim 16 wherein the secondary muffler case includes Nsets of muffler rings, the N sets of muffler rings being axially alignedand radially spaced to provide N−1 fluid passages therein, wherein N isgreater than or equal to
 3. 19. A method of operating a chiller system,the chiller system comprising a muffler, the muffler further comprising:an upstream case having a fluid inlet; a downstream case connected tothe upstream case at a downstream end of the upstream case, thedownstream case having a fluid outlet; the upstream case having aplurality of axially adjacent outer muffler rings and a plurality ofaxially adjacent inner muffler rings, the outer muffler rings beingaxially coextensive and a radially exterior to the inner muffler ringsand defining a fluid inlet passage therebetween, and wherein the outermuffler rings and inner muffler rings are a metal mesh material, whereinthe upstream case comprises N sets of muffler rings including the outermuffler rings and the inner muffler rings, the N sets of muffler ringsbeing axially aligned and radially spaced to provide N−1 fluid passagestherein, wherein N is greater than or equal to 3 to define at least afirst intermediate set of muffler rings which are radially between theouter muffler rings and inner muffler rings, to thereby provide a centerchamber and at least two flow passages axially aligned and radiallyspaced between the sets of muffler rings, wherein a first flow passageof the at least two flow passages is between the inner muffler rings andthe first intermediate set of muffler rings and a second flow passage ofthe at least two flow passages is between the outer muffler rings andthe first intermediate set of muffler rings, the method comprising:muffling noise so that over an octave band of 80 Hz to 130 Hz, a soundpressure level is between approximately 78 dBA-Wtg and approximately 80dBA-Wtg.
 20. The method of claim 19, wherein muffling noise over a onethird octave band, from static to 1000 Hz, results in an average soundpressure level of 81.7 dBA.